Wavy Heat Exchanger Core With Integrated Manifold Passages

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Solution Overview

Problem

Conventional heat exchanger assembly processes are costly and cumbersome, limiting the configuration and efficiency of thermal energy transfer due to complex construction and assembly requirements.

Innovation Solution

A heat exchanger design featuring non-linear fluid passages with varying lateral passages that increase in length and depth, defined by cutouts, which are formed using additive manufacturing to optimize thermal energy exchange and reduce manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional plate-fin heat exchanger assembly processes are used with stacked and brazed components, then structural integrity is achieved, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (manifold and heat exchanger core) into a single integrated additive manufactured structure. The manifold passages and core passages are merged into one continuous non-linear flow path, eliminating the need for separate brazing operations and reducing assembly complexity while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention changes the manufacturing method from conventional stacking and brazing to additive manufacturing. This parameter change enables complex non-linear geometries and varying passage cross-sections that would be difficult or impossible to achieve with traditional methods, thereby reducing assembly complexity

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If complex stacked component assembly is used, then thermal energy transfer capability is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidthermal energy transfer efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent employs non-linear curved passages instead of straight linear paths. The sinusoidal and varying cross-section passages increase the surface area for heat exchange and enhance turbulence, improving thermal energy transfer efficiency while the additive manufacturing process keeps costs competitive

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Productivity

If linear fluid passages are used, then manufacturing is simpler, but thermal energy transfer efficiency decreases

Engineering Contradiction:

Improvethermal energy transfer efficiencyVSAvoidpassage configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements non-linear sinusoidal passages with varying cross-sections that increase thermal energy transfer efficiency through enhanced turbulence and increased surface area, while the additive manufacturing process handles the complexity without significantly increasing manufacturing difficulty

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Productivity

If multiple separate components are stacked and brazed, then structural integrity is achieved, but assembly time and cost increase

Engineering Contradiction:

Improveassembly efficiencyVSAvoidnumber of components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the manifold and core into a single additive manufactured component with integrated passages. This eliminates multiple brazing operations and reduces the number of parts to assemble, significantly improving assembly efficiency while the monolithic structure maintains structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances thermal energy transfer efficiency and reduces manufacturing costs by allowing for more efficient fluid flow and turbulence, while maintaining seamless side entry and exit paths without compromising thermal performance.

Implementation Method 1

a plurality of second fluid passages through which a second fluid is flowed from the second fluid inlet to the second fluid outlet to exchange thermal energy with the first fluid

Methodology Applied

Scientific EffectThermal energy exchange: Conduction (thermal)

Implementation Method 2

This design enhances thermal energy transfer efficiency and reduces manufacturing costs by allowing for more efficient fluid flow and turbulence

Methodology Applied

Scientific EffectTurbulence: Turbulence

Data Source

PatentEP4109027A1Wavy adjacent passage heat exchanger core and manifold

Publication Date: 2022.12.28 HAMILTON SUNDSTRAND CORP

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AI summary

A heat exchanger includes a first fluid inlet (14), a first fluid outlet (16), a second fluid inlet (24), a second fluid outlet (26), and a core section (129. The core section includes a plurality of first fluid passages (40) through which a first fluid is flowed, and a plurality of second fluid passages (42) through which a second fluid is flowed to exchange thermal energy with the first fluid. The first fluid passages and the second fluid passages extend non-linearly along a length of the first fluid passages and the second fluid passages between a first core end and a second core end opposite the first core end. A manifold (56) is operably connected to the plurality of first fluid passages. The manifold includes a plurality of lateral passages intersecting the plurality of first fluid passages. The plurality of lateral passages vary in length depending on distance from a fluidly upstream end of the core section.